Slide measuring system for filling pouches and associated method

ABSTRACT

Systems and methods for metering a granular material for packaging in pouches are disclosed. A system includes a hopper structured and arranged to hold a granular material in a hopper cavity. The system also includes a measuring system including a measuring cavity and a tube that is slidable in the hopper cavity between a first position unaligned with the measuring cavity and a second position over and aligned with the measuring cavity. The measuring system is structured and arranged to move a portion of the granular material from the hopper cavity to the measuring cavity when the tube is in the first position. The measuring system is structured and arranged to move the portion of the granular material from the measuring cavity to a pouch making machine using pressurized gas when the tube is in the second position.

RELATED APPLICATION

This application claims priority to U.S. Provisional Application No.61/920,972, filed on Dec. 26, 2013, the contents of which are herebyincorporated by reference in their entirety.

FIELD

This disclosure relates generally to systems and methods for fillingpouches with granular material and, more particularly, to providingmeasured portions of smokeless tobacco to a pouch making machine in acontinuous operation.

SUMMARY

Smokeless tobacco, such as dipping tobacco, snus, etc., is commonlypackaged in pouches that are provided to the consumer in a liddedcylindrical container (e.g., a can). Each pouch may include an amount oftobacco contained in a paper case.

In accordance with aspects disclosed herein, there is a system andmethod for measuring (metering) tobacco for packaging in pouches. Asystem includes a hopper structured and arranged to hold a granular(shredded, ground) material in a hopper cavity. The system also includesa measuring system including a measuring cavity and a tube that isslidable in the hopper cavity between a first position unaligned withthe measuring cavity and a second position over and aligned with themeasuring cavity. The measuring system is structured and arranged tomove a portion of the granular material from the hopper cavity to themeasuring cavity when the tube is in the first position. The measuringsystem is structured and arranged to move the portion of the granularmaterial from the measuring cavity to a pouch making machine usingpressurized gas when the tube is in the second position.

According to another aspect, there is a system for measuring tobacco forpackaging in pouches. The system includes a hopper structured andarranged to hold a granular material in a hopper cavity. The system alsoincludes a measuring system including: a plurality of measuringcavities; a plurality of tubes slidable in the hopper cavity; a vacuumsource; and a pressure source. The measuring system is structured andarranged to move the plurality of tubes to a first position thatuncovers the plurality of measuring cavities. The measuring system isalso structured and arranged to fill the plurality of measuring cavitieswith respective portions of the granular material using the vacuumsource while the plurality of tubes are in the first position. Themeasuring system is additionally structured and arranged to move theplurality of tubes to a second position over and aligned with theplurality of measuring cavities. The measuring system is furtherstructured and arranged to move the respective portions of the granularmaterial from the plurality of measuring cavities to a pouch makingmachine using the pressure source while the plurality of tubes are inthe second position.

According to another aspect, there is a method for measuring tobacco forpackaging in pouches. The method includes: providing granular materialto a sifter using a feeder; sifting the granular material into a hopper;measuring a portion of the granular material in a measuring cavity;moving the portion of the granular material from the measuring cavity toa pouch making machine; and making a pouch encapsulating the portion ofgranular material. The measuring includes: moving a tube to a firstposition unaligned with the measuring cavity; moving the portion of thegranular material into the measuring cavity using gravity and/or vacuum;and moving the tube to a second position over and aligned with themeasuring cavity. The moving the portion of the granular material fromthe measuring cavity to the pouch making machine includes applyingcompressed gas to the measuring cavity to move the portion of thegranular material through a flowpath extending between the measuringcavity and the pouch making machine.

BRIEF DESCRIPTION OF THE DRAWINGS

Various aspects are further described in the detailed description whichfollows, in reference to the noted plurality of drawings by way ofnon-limiting examples of embodiments, in which like reference numeralsrepresent similar parts throughout the several views of the drawings.

FIG. 1 shows an exemplary pouch making system, in accordance herewith;

FIG. 2 shows various aspects of the pouch making system, in accordanceherewith;

FIG. 3 shows additional aspects of the pouch making system, inaccordance herewith;

FIG. 4 shows additional aspects of the pouch making system, inaccordance herewith;

FIG. 5 shows additional aspects of the pouch making system, inaccordance herewith;

FIG. 6 shows additional aspects of the pouch making system, inaccordance herewith;

FIG. 7 shows additional aspects of the pouch making system, inaccordance herewith;

FIG. 8 shows additional aspects of the pouch making system, inaccordance herewith;

FIG. 9 shows additional aspects of the pouch making system, inaccordance herewith;

FIG. 10 shows additional aspects of the pouch making system, inaccordance herewith;

FIG. 11 shows additional aspects of the pouch making system, inaccordance herewith;

FIG. 12 shows additional aspects of the pouch making system, inaccordance herewith;

FIG. 13 shows additional aspects of the pouch making system, inaccordance herewith;

FIG. 14 shows additional aspects of the pouch making system, inaccordance herewith;

FIG. 15 shows additional aspects of the pouch making system, inaccordance herewith; and

FIG. 16 shows a flow diagram of a method in accordance herewith.

DETAILED DESCRIPTION

Various aspects will now be described with reference to specific formsselected for purposes of illustration. It will be appreciated that thespirit and scope of the apparatus, system and methods disclosed hereinare not limited to the selected forms. Moreover, it is to be noted thatthe figures provided herein are not drawn to any particular proportionor scale, and that many variations can be made to the illustrated forms.Reference is now made to FIGS. 1-15, wherein like numerals are used todesignate like elements throughout.

Each of the following terms written in singular grammatical form: “a,”“an,” and “the,” as used herein, may also refer to, and encompass, aplurality of the stated entity or object, unless otherwise specificallydefined or stated herein, or, unless the context clearly dictatesotherwise. For example, the phrases “a device,” “an assembly,” “amechanism,” “a component,” and “an element,” as used herein, may alsorefer to, and encompass, a plurality of devices, a plurality ofassemblies, a plurality of mechanisms, a plurality of components, and aplurality of elements, respectively.

Each of the following terms: “includes,” “including,” “has,” “having,”“comprises,” and “comprising,” and, their linguistic or grammaticalvariants, derivatives, and/or conjugates, as used herein, means“including, but not limited to.”

Throughout the illustrative description, the examples, and the appendedclaims, a numerical value of a parameter, feature, object, or dimension,may be stated or described in terms of a numerical range format. It isto be fully understood that the stated numerical range format isprovided for illustrating implementation of the forms disclosed herein,and is not to be understood or construed as inflexibly limiting thescope of the forms disclosed herein.

Moreover, for stating or describing a numerical range, the phrase “in arange of between about a first numerical value and about a secondnumerical value,” is considered equivalent to, and means the same as,the phrase “in a range of from about a first numerical value to about asecond numerical value,” and, thus, the two equivalently meaning phrasesmay be used interchangeably.

It is to be understood that the various forms disclosed herein are notlimited in their application to the details of the order or sequence,and number, of steps or procedures, and sub-steps or sub-procedures, ofoperation or implementation of forms of the method or to the details oftype, composition, construction, arrangement, order and number of thesystem, system sub-units, devices, assemblies, sub-assemblies,mechanisms, structures, components, elements, and configurations, and,peripheral equipment, utilities, accessories, and materials of forms ofthe system, set forth in the following illustrative description,accompanying drawings, and examples, unless otherwise specificallystated herein. The apparatus, systems and methods disclosed herein canbe practiced or implemented according to various other alternative formsand in various other alternative ways.

It is also to be understood that all technical and scientific words,terms, and/or phrases, used herein throughout the present disclosurehave either the identical or similar meaning as commonly understood byone of ordinary skill in the art, unless otherwise specifically definedor stated herein. Phraseology, terminology, and, notation, employedherein throughout the present disclosure are for the purpose ofdescription and should not be regarded as limiting.

This disclosure relates generally to systems and methods for fillingpouches with granular material and, more particularly, to providingmeasured portions of smokeless tobacco to a pouch making machine in acontinuous operation. According to aspects disclosed herein, a systemincludes a measuring system that accurately and consistently measures avolumetric amount of granular material for insertion into a pouch. Inembodiments, the measuring system includes a plurality of lanes thatmeasure a plurality of portions of the granular material simultaneously.In aspects described herein, the measuring system is arranged upstreamof a pouch making machine and provides the measured portions of granularmaterial to the pouch making machine, which creates respective poucheseach containing a measured portion of granular material.

As used herein the terms “adapted” and “configured” or “structured” and“arranged” mean that the element, component, or other subject matter isdesigned and/or intended to perform a given function. Thus, the use ofthe terms “adapted” and “configured” or “structured” and “arranged”should not be construed to mean that a given element, component, orother subject matter is simply “capable of” performing a given functionbut that the element, component, and/or other subject matter isspecifically selected, created, implemented, utilized, programmed,and/or designed for the purpose of performing the function. It is alsowithin the scope of the present disclosure that elements, components,and/or other recited subject matter that is recited as being adapted toperform a particular function may additionally or alternatively bedescribed as being configured to perform that function, and vice versa.

Granular material as used herein may refer to smokeless tobacco,including but not limited to dipping tobacco, snus, etc. However, theinvention is not limited to use with tobacco, and other non-tobaccogranular material(s) may be used within the scope of the invention.

FIG. 1 shows an exemplary system 10 in accordance herewith. Inembodiments, system 10 includes a feeder 20, sifter 30, hopper 40,measuring system 50, and pouch making machine 60. The system 10 may alsoinclude a conveyor 70 that moves empty containers (e.g., cans) 80 intoposition to receive pouches from pouch making machine 60 and that movescontainers filled with pouches away from pouch making machine 60. Thedetails of the pouch making machine 60 are not shown. Pouch makingmachine 60 may include a conventional machine such as, for example, thepouching apparatus manufactured and sold by, for example, RopakManufacturing Company, Inc. of Decatur, Ala. and MerzVerpackungsmaschinen GmbH, Lich, Germany.

In an exemplary operation of the system 10, the feeder 20 selectivelyprovides bulk granular material to the sifter 30, which de-clumps thebulk granular material with a sifting operation and provides the siftedgranular material to the hopper 40. The hopper 40 collects and holds thesifted granular material adjacent the measuring system 50. The measuringsystem 50 draws a portion of the granular material from the hopper 40into a measuring volume, and subsequently moves the measured portion ofgranular material from the measuring volume to the pouch making machine60 where the measured portion of granular material is encapsulated in apouch. The pouch containing the measured portion of granular materialmay be placed in a container 80. The various aspects of system 10 aredescribed in greater detail herein.

Still referring to FIG. 1, the feeder 20 includes an inlet 100 adaptedto receive bulk material and an outlet 105 adapted to pass the bulkmaterial to the sifter 30. The outlet 105 may include a number of pans110 a-c equal to a number of chambers included in the sifter 30. Bulkmaterial may be provided to the inlet 100 in any suitable manner,including manually (e.g., hand scooped, poured from a bag, etc.) and/orautomatically (e.g., delivered on a conveyor, etc.). A number of chutes115 a-c equal to the number of pans 110 a-c may be used to convey thebulk material from the inlet to the pans 110 a-c. The invention is notlimited to the three pans and chutes shown, and any number of may beused, including one, two, more than three, etc.

In aspects described herein, the bulk material collects in the pans 110a-c and is selectively moved from the pans 110 a-c to the sifter 30 bycontrollably agitating (e.g., shaking) the feeder 20. For example, thepans 110 a-c may be slightly inclined relative to horizontal such thatagitating the feeder causes the bulk material to move toward an open endof the pans 110 a-c and fall from the pans 110 a-c into the sifter 30 bygravity. The agitating is controlled, e.g., selectively turned on andoff, to provide a desired amount of bulk material to the sifter 30. Thecontrol may be provided by a sensor and/or by a computer-based controlprogram, or the like. The agitating may be provided in any suitablemanner, such as with an electric or pneumatic actuator.

FIGS. 2-4 show views of an exemplary implementation of sifter 30 inaccordance herewith. With specific reference to FIG. 2, sifter 30 mayinclude a number of chambers 130 a-c corresponding to the number of pans110 a-c of feeder 20. During operation, chambers 130 a-c receive bulkmaterial from feeder 20. Partitions 135 a-b may be used to divide thechambers 130 a-c. The sifter 30 is described with three chambers 130 a-cfor illustration purposes but is not limited to this or any other numberof chambers. Moreover, the invention is not limited to sifter 30including a number of chambers equal to the number of pans, andimplementations may be used in which sifter 30 has a number of chambersthat is different than the number of pans.

According to aspects described herein, and as shown in FIGS. 3 and 4,each chamber 130 a-c includes a screen 140 in a bottom surface of thechamber and a wiper (e.g., agitator) 145 connected to a shaft 150. Inembodiments, the shaft 150 extends through all chambers 130 a-c and isconnected to the respective wiper 145 in each respective chamber, suchthat the shaft 150 moves all wipers 145 at the same time. The shaft 150may be driven (e.g., rotated in a reciprocating manner) by any suitableactuator, such as an electric motor 155 as shown in FIG. 1.

As is understood from FIGS. 2-4, sifter 30 operates to sift bulkmaterial that is held in chambers 130 a-c through screens 140, withwipers 145 assisting in breaking up the bulk material and/or pushing thebulk material through the screens 140. Tobacco pouch making equipment issensitive to the composition/characteristics of the tobacco (e.g., bulkmaterial) that is used in pouch production. The ability to control pouchweight consistently at the pouch making equipment is affected by theconsistency of the tobacco used. The more consistent the tobaccocharacteristics are, the better the pouch maker will operate. Whensticky/clumpy tobacco is used in the production, pouch weight can bedifficult to control. Moreover, when the tobacco is fed from bulkstorage containers into the pouch making machinery, it can be difficultto provide consistent material characteristics. Many times, tobaccocoming from bulk storage containers is stuck together in clumps.

As described herein, sifter 30 is arranged downstream of bulk materialfeeder 20 and upstream of pouch making machine 60, and is used tode-clump the granular material in order to provide consistent granularmaterial. In embodiments, sifter 30 forces the granular material to flowthrough the one or more screens 140, which have a predefined openingdimension. In some aspects, when the granular material does not easilyflow through screen 140 by gravity alone, wiper 145 pushes the granularmaterial through the screen 140. The wiper 145 also breaks up clumps ofthe bulk material, which helps the material pass through screen 140.

FIGS. 5-7 show views of an exemplary implementation of hopper 40 inaccordance herewith. With specific reference to FIG. 5, hopper 40 isarranged below sifter 30 and receives sifted granular material that haspassed through screens 140. A diverter 160, shown in FIGS. 1 and 5, maybe used to guide the granular material as it travels by gravity fromsifter 30 to hopper 40.

According to aspects described herein, and as shown in FIGS. 6 and 7,hopper 40 includes a front wall 170, back wall 175, bottom plate 180,and end blocks 185 that define a hopper cavity 190 that receives andholds sifted granular material adjacent the measuring system. Inembodiments, the front wall 170, back wall 175, and bottom plate 180 arestationary, and the end blocks 185 are moveable relative to thestationary elements. In one example, end blocks 185 are fixedlyconnected to a slide 200 that moves transversely, e.g., along arrow 205,and in a reciprocating fashion relative to stationary front wall 170,back wall 175, bottom plate 180. Slide 200 may be moved using anysuitable actuator, such as an electric actuator, pneumatic actuator, orthe like. The movement of blocks 185 causes movement of the granularmaterial within the hopper cavity 190, which prevents accumulation ofthe granular material at the ends of the hopper cavity 190 adjacent theblocks 185. The movement of the granular material within hopper cavity190 that is caused by moving the blocks 185 also assists in moving thegranular material over the measuring holes 210 in the bottom plate 180,as described in greater detail below.

FIG. 8 shows aspects of an exemplary measuring system 50 as describedherein. In embodiments, bottom plate 180 of hopper 40 includes holes 210that are structured and arranged to be filled with a volume of granularmaterial from hopper cavity 190. After one of the holes 210 is filledwith granular material, a tube 215 is moved over and in precisealignment with the filled hole 210. The tube 215 may be moved by a tubecarrier 220 that is connected to slide 200 as described herein. Aconduit 225 may be connected to one end of tube 215 between tube 215 andpouch making machine 60. In embodiments, when tube 215 is aligned overhole 210, the measured portion of granular material in hole 210 is movedout of hole 210, through tube 215, and through conduit 225 to pouchmaking machine 60. In aspects, the pouch making machine 60 encapsulates(encloses) the measured portion of granular material in a pouch “P”(e.g., a paper pouch) and drops pouch “P” into a container 80 (e.g., acylindrical can). The filling of hole 210 with granular material may beaccomplished using gravity and/or vacuum, and moving the granularmaterial out of the hole 210 may be accomplished using pressurized gas,as described in greater detail herein. As depicted in FIG. 8, there maybe plural holes 210, tubes 215, and conduits 225 associated with asingle hopper 40 and/or a single pouch making machine 60.

FIG. 9 shows an exemplary arrangement of tubes 215, tube carrier 220,and conduits 225 as described herein. In embodiments, a tube carrier 220holds two tubes 215 and includes hardware 230 (e.g., clamps, etc.) forconnecting to slide 200 (as shown in FIG. 8), such that tube carrier 220moves with slide 200. The tube carrier 200 is not limited to theconfiguration shown in FIG. 9, and other configurations may be usedwithin the scope of the invention.

FIGS. 10-12 show an exemplary operation of measuring a portion ofgranular material using measuring system 50 as described herein. Asshown in FIG. 10, in embodiments a pin 235 is arranged within hole 210in bottom plate 180. An uppermost portion of pin 235 is situated withinhole 210 (e.g., recessed from a surface of bottom plate 180), such thata cavity 240 is defined in hole 210 by bottom plate 180 and pin 235.Cavity 240 may also be referred to herein as a measuring cavity. Thevolume of cavity 240 may be selectively adjusted (e.g., increased ordecreased) by moving pin 235 up or down within hole 210, as described ingreater detail herein.

Still referring to FIG. 10, tube 215 is atop bottom plate 180 and ismoveable (e.g., slidable) back and forth along the top of plate in thedirections indicated by arrow 205. The tube 215 has a hollow interiorthat, in embodiments, is substantially a same diameter as hole 210.Although not shown in FIG. 10, an upper end of tube 215 is connected toconduit 225, such that the hollow interiors of tube 215 and conduit 225combine to form a flow path extending from measuring system 50 to pouchmaking machine 60. The movement of tube 215 in the direction of arrow205 may be effectuated via slide 200 as described with respect to FIG.8, e.g., by connecting tube 215 to tube carrier 220 that is connected toslide 200. In the position shown in FIG. 10, tube 215 is beside (e.g.,not covering) hole 210, which permits granular material 245 in hoppercavity 190 to move into cavity 240 by gravity and/or vacuum.

In embodiments, pin 235 has a hollow axial bore 250. A screen 247 may beprovided at a first end of bore 250 (e.g., adjacent cavity 240) toprevent granular material 245 from entering bore 250. In aspects, athree-way valve 255 is connected to a second end of bore 250, a vacuumsource 260, and a pressure source 265. A controller 270, such as aprogrammable computer device or the like, may be operatively connectedto valve 255 to cause valve 255 to place one of vacuum source 260 andpressure source 265 in fluid communication with bore 250. In thismanner, valve 255 and controller 270 may be used to selectively applyvacuum or pressurized gas (e.g., compressed air) to bore 250.

With continued reference to FIG. 10, cavity 240 is filled with granularmaterial 245 when tube 215 is moved to a position to the side of hole210 (e.g., not covering hole 210). In this position, some of thegranular material 245 in hopper cavity 190 falls into cavity 240 bygravity. In embodiments, controller 270 causes valve 255 to connectvacuum source 260 to bore, which applies a vacuum to bore 250 (e.g.,negative pressure indicated by downward arrow shown in bore 250), whichaids in moving granular material 245 from hopper cavity 190 into cavity240.

As shown in FIG. 11, after cavity 240 is filled with granular material245, tube 215 is moved laterally within hopper cavity 190 (e.g., slidalong plate 180) to a position over and aligned with cavity 240. Inparticular, the hollow interior of tube 215 is vertically aligned withhole 210 and cavity 240. Movement of tube 215 in the direction of arrow275 pushes excess granular material 245 away from the space immediatelyover cavity 240, which provides a trimming action similar to dragging aknife across the top of a measuring cup that is overfilled withmaterial. In this manner, implementations of the invention preciselymeasure a portion of granular material 245 in cavity 240. Inembodiments, valve 255 keeps vacuum source 260 connected to bore 250while tube 215 moves from the position shown in FIG. 10 to the positionshown in FIG. 11.

As shown in FIG. 12, while tube 215 is in the aligned position overcavity 240, controller 270 causes valve 255 to disconnect vacuum source260 from bore 250 and then connect pressure source 265 to bore 250. Thisapplies pressurized gas (e.g., compressed air) to bore 250 (e.g., asindicated by upward arrow shown in bore 250), which pushes the measuredportion of granular material 245 out of cavity 240, through tube 215 andconduit 225 (as shown in FIG. 8), and into pouch making machine 60 (asshown in FIG. 8). In embodiments, controller 270 causes valve 255 tokeep pressure source 265 connected to bore 250 for a predeterminedamount of time that is sufficient to move the measured portion ofgranular material 245 from cavity 240 to the pouch making machine. Afterthe predetermined amount of time, controller 270 causes valve 255 todisconnect pressure source 265 from bore 250 and then connect vacuumsource 260 to bore 250, and tube 215 moves back to the position shown inFIG. 10 to repeat the cycle.

In additional embodiments, a fluid (e.g., water) may be injected intobore 250 while pressure source 265 is connected to bore 250 as describedin FIG. 12. The fluid may be injected into plumbing downstream ofpressure source 265, or alternatively may be injected at a separate portof pin 235. For example, an atomized water source 273 may be provided toinject atomized water into bore 250.

The timing of the fluid injection may be optimized based on parametersincluding, but not limited to: duration of applying pressurized gas tobore 250 (e.g., the predetermined amount of time described with respectto FIG. 12); pressure of pressurized gas; and volume of cavity 240. In anon-limiting example, the pressure source 265 provides compressed air ata pressure of about 20 to 30 psi, the predetermined amount of time ofapplying pressurized gas to bore 250 is in a range of about 50 to about160 milliseconds, and the amount of time of fluid injection is about 30to about 40 milliseconds, with the fluid injection occurring nearer thebeginning of the duration of applying pressurized gas than the end. Theinvention is not limited to the values in this example, however, andother suitable pressures and/or durations may be used within the scopeof the invention.

With continued reference to FIGS. 10-12, the volume of cavity 240 may beadjusted by moving pin 235 up or down within hole 210. For example,moving pin 235 upward in hole 210 makes cavity 240 smaller, and movingpin downward in hole 210 makes cavity 240 larger. The pin 235 may bemoved up or down in hole 210 using any suitable actuator, such as amanual and/or automated screw actuator or the like.

In accordance with aspects described herein, the volume of cavity 240 isadjusted based on a determined weight of a number of pouches that areproduced by the pouch making machine 60. For example, a number ofpouches may be made by pouch making machine 60, with each pouchincluding a portion of granular material that is measured using cavity240. The number of pouches may be weighed, the weight of the number ofpouches may be compared to an upper threshold and a lower threshold, andthe volume of cavity 240 may be adjusted based on comparing thedetermined weight to the upper and lower thresholds. For example, whenthe determined weight is less than the lower threshold, then pin 235 ismoved downward in hole 245, thereby making cavity 240 larger andincreasing the mass of granular material per pouch. When the determinedweight is more than the upper threshold, then pin 235 is moved upward inhole 245, thereby making cavity 240 smaller and decreasing the mass ofgranular material per pouch. When the determined weight is between thelower threshold and upper threshold, the pin 235 is kept at its currentposition in hole 210, as this indicates the pouches are meeting a targetweight. In this manner, implementations of the invention provide afeedback loop for adjusting the volume of cavity 240, which adjusts themass of granular material in each pouch that is produced using cavity240.

As described herein, system 10 may include plural lanes simultaneouslymaking pouches filled with granular material. For example, as shown inFIGS. 1 and 8, there may be ten lanes L1-L10, although the invention isnot limited to this number and any desired number of lanes may be used.Each lane may include: at least one hole 210 with an associated cavity240 and pin 235; a tube 215; and a conduit 225. When plural lanes areused, the volume of each respective cavity 240 may be individuallyadjusted based on determined weight of the pouches produced in thatparticular lane as already described herein. For example, with referenceto FIG. 1, a conveyor system 70 may be structured and arranged tosimultaneously move plural empty containers 80 into alignment with theplural lanes at the output of pouch making machine 60, such that therespective containers 80 are simultaneously filled with pouches fromrespective ones of the lanes. The position of each container 80 may betracked throughout the entire system, and each container 80 may beassociated with the particular one of the lanes from which it wasfilled. Each container 80 may be weighed after being filled, and thevolume of cavity 240 in the lane associated with the weighed container80 may be adjusted based on the weight of the container 80 independentof the cavities 240 of the other lanes.

FIGS. 13 and 14 show an exemplary operation of measuring system 50′ inwhich each lane includes one tube 215, two holes 210 a and 210 b, twopins 235 a and 235 b, and two cavities 240 a and 240 b. As shown inFIGS. 13 and 14, tube 215 moves back and forth to positions aligned overthe respective holes 210 a and 210 b. When tube 215 is aligned over hole210 a, as shown in FIG. 13, the measured portion of granular material incavity 240 a is expelled from cavity 240 a through tube 215 by applyingpressurized gas (e.g., compressed air) to bore 250 a of pin 235 a, e.g.,in a manner similar to that described with respect to FIG. 12. Also whentube 215 is aligned over hole 210 a, as shown in FIG. 13, hole 210 b isuncovered and cavity 240 b fills with granular material from hoppercavity 190, e.g., in a manner similar to that described with respect toFIG. 10.

FIG. 14 depicts tube 215 moved to a position over and aligned with hole210 b, e.g., after the operation shown in FIG. 13. As shown in FIG. 14,when tube is over hole 210 b, the measured portion of granular materialin cavity 240 b is expelled from cavity 240 b through tube 215 byapplying pressurized gas (e.g., compressed air) to bore 250 b of pin 235b, and cavity 240 a fills with granular material from hopper cavity 190.After the operation shown in FIG. 14, tube 215 moves back to theposition shown in FIG. 13 and the cycle repeats.

In embodiments, vacuum source 260 may be used to assist filling cavities240 a and 240 b in a manner similar to that described with respect toFIG. 10. For example, in the position shown in FIG. 13, pressure source265 is applied to bore 250 a for a predetermined amount of time, whilevacuum source 260 is applied to bore 250 b. The vacuum remains on bore235 b while tube moves from the position shown in FIG. 13 to theposition shown in FIG. 14. When tube 215 is aligned over hole 210 b,vacuum source 260 is disconnected from bore 250 b and pressure source265 is connected to bore 250 b for a predetermined amount of time.Concurrently, vacuum source 260 is connected to bore 250 a to assist infilling cavity 240 a with granular material. Vacuum source 260 remainsconnected to bore 250 a until tube 215 moves back to the position shownin FIG. 13. The amount of vacuum may be within a range of 0 to 10 inchesof mercury, although any suitable amount of vacuum may be used withinthe scope of the invention. Each pin 235 a and 235 b may be connected toa respective valve 255 a and 255 b, which may be controlled by acontroller (e.g., controller 270 as described herein).

FIG. 15 shows portions of an exemplary measuring system 50 includingtwenty pins 235 a-t, which may be used in a ten lane system such as thatshown in FIGS. 1, 6, and 8. In embodiments, the respective valveassociated with each respective pin is connected to a vacuum manifold300 and a pressure manifold 305. For example, pin 235 a is connected tovalve 255 a (e.g., in a manner similar to that described with respect toFIG. 10), with valve 255 a being connected to vacuum manifold 300 and apressure manifold 305. The vacuum manifold 300 is connected to vacuumsource 260, and pressure manifold 305 is connected to pressure source265. Structure 310 may house all the valves associated with all therespective pins 235 a-t. Structure 310 may additionally or alternativelyhouse manual and/or automated mechanisms for adjusting the height ofpins 235 a-t to adjust cavity volumes as described herein, eitherindividually or as a group.

The system as described herein may thus include ten lanes, with eachlane including one tube 215, one conduit 225, two holes 210 a and 210 b,two cavities 240 a and 240 b, and two pins 235 a and 235 b. All tentubes and conduits may be moved as a group in a reciprocating fashion,e.g., as shown in FIG. 8, between a first position over a first tenholes and a second position over a second ten holes. When the ten tubesare in the first position over the first ten holes, a first ten measuredportions of granular material are moved from a first ten cavities to thepouch making machine, while a second ten cavities are simultaneouslyfilled with granular material from the hopper cavity. When the ten tubesare in the second position over the second ten holes, a second tenmeasured portions of granular material are moved from a second tencavities to the pouch making machine, while the first ten cavities aresimultaneously filled with granular material from the hopper cavity.

In embodiments, a level sensor may be used to maintain a proper level ofgranular material in hopper cavity 190. For example, a laser sensor,electronic eye, or the like, may be used to detect when the amount ofgranular material in hopper cavity 190 falls below a predefinedthreshold. Any desired number and/or type(s) of level sensors may beused. A controller may be connected to the level sensor. The controllerconnected to the level sensor may be the same as controller 270, or maybe a different controller. When the level sensor detects the amount ofgranular material in hopper cavity 190 falls below a predefinedthreshold, the controller may activate the sifter 30 for a predefinedamount of sifting time (e.g., 2 seconds) to move granular material fromthe sifter 30 to the hopper 40. Activating the sifter 30 may include,for example, the controller sending a signal to electric motor 155 tocause rotation of shaft 150 that moves wipers 145 for the predefinedamount of sifting time.

After the predefined amount of sifting time, in the event the levelsensor indicates the level of granular material in hopper 40 is abovethe predefined threshold, then the controller turns off sifter 30. Onthe other hand, in the event the level sensor indicates the level ofgranular material in hopper 40 is still below the predefined thresholdafter the predefined amount of sifting time, then the controller causesthe system to agitate feeder 20 for a predefined amount of feeder timeto move granular material from feeder 20 to sifter 30. Agitating feeder20 may include, for example, the controller sending a signal to anactuator (e.g., an electric motor) that causes vibration of pans 110 a-cof feeder 20 for the predefined amount of feeder time, which causesgranular material to move from feeder 20 into sifter 30. In aspects, thecontroller also activates sifter 30 while agitating feeder 20.

After the predefined amount of feeder time, in the event the levelsensor indicates the level of granular material in hopper 40 is abovethe predefined threshold, then the controller turns off feeder 20 andsifter 30. On the other hand, in the event the level sensor indicatesthe level of granular material in hopper 40 is still below thepredefined threshold after the predefined amount of sifting time, thenthe controller causes the system to agitate feeder 20 and activatesifter 30 again for the predefined amount of feeder time. In thismanner, the system may keep feeder 20 and sifter 30 turned on until thelevel of granular material in hopper 40 reaches the desired level.

As described herein, various aspects of system 10 may be controlledusing a controller, such as a programmable computer device or the like.For example, controller 270 may be operatively connected to elements ofsystem 10 and adapted to control at least one of the followingfunctions: detecting level of granular material in hopper 40; agitatingfeeder 20; moving wipers 145 in sifter 30; moving slide 200; controllingvalve 255; moving conveyor 70; tracking positions of containers 80 onconveyor 70 and/or throughout the system; weighing pouches in containersand comparing the weight to thresholds; and adjusting height of pins 235in holes 210 based on the comparing. For example, controller 270 may beconfigured to coordinate the timing of the movement of slide 200 withthe control of valve 255, such that vacuum or pressure is appropriatelyapplied to bore 250 based on the position of tube 215 over cavity 240(e.g., as described with respect to FIGS. 10-14). The invention is notlimited to a single controller performing these functions, and anydesired number and/or type of controllers may be used. The controller(s)may be operatively connected to sensors and/or actuators, e.g., asdescribed herein, in order to perform one or more of these functions.

FIG. 16 shows a flow diagram of a method in accordance herewith. Methodsin accordance herewith may be performed using the systems described withrespect to FIGS. 1-15 and in a manner similar to that described withrespect to those figures. The steps of FIG. 16 are described in part byreferring to reference numbers associated with elements shown in theprevious drawings. At step 410 the system provides bulk granularmaterial (e.g., tobacco), e.g., to sifter 30. This may comprise, forexample, providing bulk granular material to feeder 20 and/or agitatingfeeder 20 to cause the bulk granular material to fall out of feeder 20into sifter 30.

At step 420, the system sifts the bulk granular material. Inembodiments, this includes sifting the bulk granular material throughscreens 140 in sifter 145. This may optionally include moving wipers 145to assist in sifting the bulk granular material through screens 140.

At step 430, the system measures a portion of the sifted granularmaterial. In embodiments, the measuring includes moving a portion of thegranular material from the hopper cavity 190 to a measuring cavity 240,e.g., as described with respect to FIGS. 10-14. Step 430 may includeuncovering a cavity 240 and moving granular material 245 into the cavity240 by gravity and/or vacuum (e.g., as in FIG. 10), and trimming excessgranular material 245 away from over the cavity (e.g., as in FIG. 11).

At step 440, the system moves the measured portion of granular materialto a pouch making machine. This may include ejecting the measuredportion of granular material from the measuring cavity 240 usingcompressed air, which causes the measured portion of granular materialto travel through tube 215 and conduit 225 to pouch making machine 60.

At step 450, the system makes a pouch encapsulating the measured portionof granular material. This may include, for example, pouch makingmachine 60 forming a pouch using conventional pouch making processes. Atstep 460, the system places the pouch in a container, e.g., container80.

After step 440, one branch of the process loops back to step 430. Inthis manner, the system continues to measure new portions of thegranular material concurrently while the pouch making machine isprocessing previous measured portions of granular material.

At optional step 470, the system detects the weight of one or morepouches, compares the weight to upper and lower thresholds, and adjuststhe measuring system based on the comparing, if necessary. Step 470 mayinclude one of: moving pin 235 downward in hole 245, thereby makingcavity 240 larger and increasing the mass of granular material perpouch, when the determined weight is less than the lower threshold;moving pin 235 upward in hole 245, thereby making cavity 240 smaller anddecreasing the mass of granular material per pouch, when the determinedweight is more than the upper threshold; and not moving pin 235 when thedetermined weight is between the lower threshold and upper threshold.After step 470, the process returns to step 430 to continue measuringportions of the granular material.

Illustrative, non-exclusive examples of systems and methods according tothe present disclosure have been presented. It is within the scope ofthe present disclosure that an individual step of a method recitedherein, including in the following enumerated paragraphs, mayadditionally or alternatively be referred to as a “step for” performingthe recited action.

INDUSTRIAL APPLICABILITY

The systems and methods disclosed herein are applicable to the packagingindustry, in particular, to that portion directed to pouching, and tothe tobacco industry, in particular that portion directed to smokelesstobacco products.

The particulars shown herein are by way of example and for purposes ofillustrative discussion only and are presented in the cause of providingwhat is believed to be the most useful and readily understooddescription of the principles and conceptual aspects. In this regard, noattempt is made to show structural details in more detail than isnecessary for fundamental understanding, the description taken with thedrawings making apparent to those skilled in the art how the severalforms disclosed herein may be embodied in practice.

It is noted that the foregoing examples have been provided merely forthe purpose of explanation and are in no way to be construed aslimiting. While aspects have been described with reference to anexemplary embodiment, it is understood that the words which have beenused herein are words of description and illustration, rather than wordsof limitation. Changes may be made, within the purview of the appendedclaims, as presently stated and as amended, without departing from thescope and spirit of the present disclosure in its aspects. Althoughaspects have been described herein with reference to particular means,materials, and/or embodiments, the present disclosure is not intended tobe limited to the particulars disclosed herein; rather, it extends toall functionally equivalent structures, methods and uses, such as arewithin the scope of the appended claims.

What is claimed:
 1. A system for metering a granular material forpackaging in pouches, the system comprising: a hopper defining a hoppercavity configured to hold a granular material; and a measuring systemincluding a first measuring cavity, a second measuring cavity differentthan the first measuring cavity, and a tube that is slidable in thehopper cavity between a first position unaligned with the firstmeasuring cavity and a second position over and aligned with the firstmeasuring cavity, the tube being over and aligned with the secondmeasuring cavity in the first position and unaligned with the secondmeasuring cavity in the second position, the measuring system beingconfigured to move a first portion of the granular material from thehopper cavity to the first measuring cavity when the tube is in thefirst position, the measuring system being configured to move the firstportion of the granular material from the first measuring cavity to apouch making machine using pressurized gas when the tube is in thesecond position, the measuring system being configured to fill thesecond measuring cavity with a second portion of the granular materialwhen the tube is in the second position, and the measuring system beingconfigured to move the second portion of the granular material from thesecond measuring cavity to the pouch making machine when the tube is inthe first position.
 2. The system of claim 1, further comprising: aconduit connected to the tube, wherein the tube and the conduit define aflow path between the first measuring cavity and the pouch makingmachine when the tube is in the second position.
 3. The system of claim1, wherein the first measuring cavity is in a bottom plate of thehopper.
 4. The system of claim 1, wherein the measuring systemcomprises: a pin having a bore that is in fluid communication with thefirst measuring cavity; a valve configured to selectively connect avacuum source with the bore; and a pressure source in fluidcommunication with the bore.
 5. The system of claim 4, furthercomprising: a water source that is structured and arranged to injectatomized water into the bore.
 6. The system of claim 4, furthercomprising: a screen at an end of the pin adjacent the first measuringcavity.
 7. The system of claim 4, wherein a location of the pin within ahole defines a volume of the first measuring cavity, and the location ofthe pin within the hole is adjustable to selectively adjust the volumeof the first measuring cavity.
 8. The system of claim 7, furthercomprising: a controller configured to detect a weight of at least onepouch made by the pouch making machine with the granular material fromthe first measuring cavity, compare the weight to an upper threshold anda lower threshold, and change the location of the pin in the hole basedon the comparison.
 9. The system of claim 1, wherein the tube isconnected to a slide that causes the tube to move in a reciprocatingmanner between the first position and the second position; and thehopper includes moveable end blocks connected to the slide.
 10. Thesystem of claim 1, further comprising: a sifter disposed upstream of thehopper to sift the granular material as the granular material moves tothe hopper.
 11. The system of claim 10, wherein the sifter defines acompartment including a screen and a moveable wiper, and the granularmaterial moves through the screen to the hopper.
 12. The system of claim11, further comprising: a feeder disposed upstream of the sifter andconfigured to provide the granular material to the sifter.
 13. Thesystem of claim 12, further comprising: a level sensor in the hopper;and a controller that is configured to move the wiper in the sifter,agitate the feeder, or move the wiper in the sifter and agitate thefeeder based on a signal from the level sensor.
 14. The system of claim1, wherein the granular material is tobacco.
 15. A system for metering agranular material for packaging in pouches, the system comprising: ahopper defining a hopper cavity that is configured to hold a granularmaterial; and a measuring system including, a first plurality ofmeasuring cavities, a second plurality of measuring cavities differentfrom the first plurality of measuring cavities, a plurality of tubesslidable in the hopper cavity, a vacuum source, and a pressure source,the measuring system being configured to move the plurality of tubes toa first position that uncovers the first plurality of measuringcavities, the plurality of tubes being over and aligned with the secondplurality of measuring cavities in the first position, fill the firstplurality of measuring cavities with first respective portions of thegranular material using the vacuum source when the plurality of tubesare in the first position, move the plurality of tubes to the secondposition over and aligned with the plurality of first measuring cavitiesand fill the second plurality of measuring cavities with secondrespective portions of the granular material when the plurality of tubesare in the second position, move the first respective portions of thegranular material from the first plurality of measuring cavities to apouch making machine using the pressure source when the plurality oftubes are in the second position, and move the second respectiveportions of the granular material from the second plurality of measuringcavities to the pouch making machine when the plurality of tubes are inthe first position.
 16. The system of claim 15, wherein the plurality oftubes are connected to slide that causes the plurality of tubes to movein a reciprocating manner between the first position and the secondposition, and the hopper includes moveable end blocks connected to theslide.
 17. The system of claim 15, wherein each one of the firstplurality of measuring cavities has a volume that is selectivelyadjustable.
 18. The system of claim 15, wherein the measuring systemincludes a plurality of pins corresponding to the first plurality ofmeasuring cavities, each one of the plurality of pins includes an axialbore in fluid communication with a respective one of the first pluralityof measuring cavities and a valve that selectively places the axial borein fluid communication with the vacuum source or the pressure source.19. The system of claim 15, further comprising: a sifter disposedupstream of the hopper and configured to sift the granular material intothe hopper; a feeder disposed upstream of the sifter and configured toprovide the granular material to the sifter; a level sensor in thehopper; and a controller configured to turn on the sifter, agitate thefeeder, or turn on the sifter and agitate the feeder based on a signalfrom the level sensor.
 20. The system of claim 15, wherein the granularmaterial is tobacco.
 21. A method of metering a granular material forpackaging in pouches, the method comprising: providing granular materialto a sifter using a feeder; sifting the granular material into a hopper;measuring a first portion of the granular material in a first measuringcavity; moving the first portion of the granular material from the firstmeasuring cavity to a pouch making machine; measuring a second portionof the granular material in a second measuring cavity; moving the secondportion of the granular material from the first measuring cavity to thepouch making machine; making a pouch encapsulating the first portion ofthe granular material; and making a pouch encapsulating the secondportion of the granular material, the measuring including moving a tubeto a first position unaligned with the first measuring cavity and overand aligned with the second measuring cavity, moving the first portionof the granular material into the first measuring cavity using gravity,vacuum, or gravity and vacuum when in the first position, and moving thetube to a second position over and aligned with the first measuringcavity and unaligned with the second measuring cavity, moving the firstportion of the granular material from the first measuring cavity to thepouch making machine when the tube is in the second position, moving thesecond portion of the granular material into the second measuring cavitywhen the tube is in the second position, and moving the second portionof the granular material from the second measuring cavity to the pouchmaking machine when the tube is in the first position.
 22. The method ofclaim 21, wherein the granular material is tobacco.
 23. The method ofclaim 21, further comprising: determining a weight of a selected numberof pouches produced; comparing the weight of the selected number ofpouches to an upper threshold and a lower threshold; and adjusting avolume of the first measuring cavity based on the comparison.
 24. Themethod of claim 23, wherein the adjusting the volume of the firstmeasuring cavity includes moving a movable pin within a hole of a bottomplate of the first measuring cavity.
 25. The method of claim 21, whereinthe tube is connected to a slide that causes the tube to move in areciprocating manner between the first position and the second position,and moving the tube includes moving end blocks of the hopper along withthe tube to displace granular material positioned against the endblocks, the end blocks of the hopper being connected to the slide.